Stain filler combination for wood



Patented Mar. 24, 1953 STAIN FILLER COMBINATION FOR WOOD John W. Mayors,Grosse Ile, Mich., assignor to Chadeloid Corporation, Wilmington, Del.,a

corporation of Delaware No Drawing. Application July 21,1949, Serial No.106,093

3 Claims. 1 g

This application deals with a method of finishing wood, and inparticular with the method of staining and filling wood, and with acomposition therefor.

Still more particularly it deals with a combination stain and filler ofthe mahogany type.

' This application is a continuation-in-part of my co-pendingapplication, Serial No. 693,803. filed August 29, 1946, now abandoned;

The methods customarily used heretofore for finishing wood surfacescomprised the following steps: (a) the wood article is sanded and thenbrushed or blown free of any dust or wood particles so as to produce asmooth surface; (b) the color of the wood is brought to a uniform hue orat least to a state of equal depth of color by sap staining the lightercolored parts or sections; the articles are then stained to the colordesired; (d) in the case of water stains used in step (c), the grain ofthe wood will have been roughened and must be leveled by applying a washcoat of shellac and then lightly sanding; (e) a glaze or sealer coat isapplied in order to seal the surface of the wood whereby penetration andthus coloring of the wood by the succeeding filler coat is prevented;(f) the filler coat is applied, allowed to set, and the excess thereofis then wiped off so that merely the pores finally contain material ofthe filler coat; and (g) transparent sealer and lacquer or varnish coatsare applied in order to give the wood surface a good protection and apleasant appearance.

Combination stain-filler materials have been used heretofore in order toavoid the many process steps required in the above described traditionalfinishing method. However, these previous combination methods are basedon the use of oilsoluble organic dyes, the compositions are ratherunstable to light and tend to blend into succeeding finishing coats.They also dry very slowly. Frequently, the materials are notsufiiciently bound in the pores of the wood so that a subsequent coatinglifts these materials from the pores and to the surface whichconsiderably impairs the appearance of the finished article.Furthermore, the pigment of such compositions is absorbed to some extentby the entire wood surface instead of only by the pores. This againaccounts for poor showing of the structure of the wood.

These oil soluble dyes, in addition, have limited solubility in mediumswhich aid in the penetration of the wood pores.

It is an object of this invention to provide a wood finish by which allthe disadvantages enumerated above are overcome.

It is an object of this invention to provide a surface coating for woodwhich is characterized by a high degree of color stability.

It is another object of this invention to provide o 2 H a surfacecoating for wood which is characterized by high brilliance. I

It is another object of this invention to provide a surface coating forwood which is free of oils and based upon vehicles having a penetratingeffect on the pores of the wood.

It is another object of this invention to provide a surface coating forwood which may be applied in a'single step.

It is another object of this invention to pro-, vide a surface coatingfor wood which shows an excellent sealing action against lacquers andvar-. nishes subsequently applied thereto.

It is still another object of thisinvention to provide a porefiller forwood which is not lifted by succeeding finishing coats.

It is still another object of this invention-to provide a stain andfiller of the mahogany type whichdeposits in the pores of the woodan-inert dark pigment which wipes clear of the surface of the wood andleaves a-brilliant finish.

These and other objects are accomplished by mixing together a resinousbinder soluble in compounds bearing hydroxyl groups and in hydrocarbondistillates, inert porefiller materialwith or without a dispersing agenttherefor, activated charcoal together-with other inert pigments forcoloring the pores of wood, dye stuffs soluble in compounds bearing ahydroxyl radical and a solvent-vehicle made up of single solvents havingdissolving power for both the resinous binderand the dyestuffs, ormixtures of compatible solvents which are capable of bringing andholding a homogeneous mixture the resinous binder and the dyestuifs andthen applying the mixture to the surface of the wood.

The brilliant stains and fillers of this invention utilize as a'basicingredient activated charcoal. This material is prepared bysubjectingdense charcoal to the action of steam at very high pres:-

sure.

' Mahogany finishes utilizing activated. charcoal are immediatelyrecognizable, because the.

activated charcoal composition wipes to a clear brilliant finish, withthe charcoal deposited in the pores of the wood.

In order to maintain the above characteristics, it 'is necessary thatthe activated charcoal be present in very definite quantities. If toogreat a quantity of charcoal is present, the stain turns muddy inappearance. Quantities of activated charcoal up to about 18% may be useddepending upon the depth of color of the stain, but it is preferable formost purposes to utilize quantities in the range of 4 to 10% by weightof the solids.

In previous mahogany finishes prepared using .carbon black, thecomposition uponwiping tend;-

ed to leave a minute layer over the entire surjface suflicient to imparta muddy off-color appearance.

Other pigments which are useful in these compositions for theirdarkening effect, mainly on the pores of wood, are black, red, andorange iron oxides, black toner, and organic lakes.

As resinous binders applicant has successfully utilized natural gums,synthetic resins, and, the like, which are soluble in solvents having as.part of their structure an hydroxyl group. Thus, for example, applicantcan use natural resins, such as manila gum, and synthetic resins, suchas phenol formaldehyde resin, glycol phthalate resins, and numerousalkyd type resins.

As for filler materials, applicant utilizes those common to the paintand varnish industry, for example, silex, barytes, expanded silica,asbestine, calcium carbonate, wood flour, starch, corn meal, and thelike.

If it is desired to cut down the time of mixing, these fillers may beadvantageously suspended by means of surface active agents, such aspolymerized organic salt of 'sulfonic acid of the alkyl aryl' type, ormorpholine and salts of alkyl sulfates, all of which are common articlesof commerce.

One of the distinctive characteristics of applic'ants composition isthat of its use of acid organic dyestuffs. These dyestuffs are notcompatible with oil vehicles and therefore are useless in, for example,linseed oil "and varnish base compositions.

In applicants composition, however, all acid organic dyestuffs areoperative for the process and the product created thereby. Thus, forexample, the following black dyestuffs were found advantageous: BuffaloBlack NBR Gene. 126%, Black Stain B34951, Nigrosine 4523J Conc. Powder;the following yellow dyestuffs: Fast Woold Yellowr3GL Cone. 125%, FastLight Yellow 3G Ex. Conc., Fast Light Yellow D3GA; the followingorange-yellow dyestuffs: Metanil Yellow 1955, Calcocid Yellow MXXX Cone;the following orange dyestuffs: Fast Light Orange 2G, Fast Light OrangeGA Conc.; the following red dyestuffs: Azo Rubin'e Ex. Gene. 133%,Calcocid Milling Red 713 Conc., Camoisine 'BA Extra Conc. CF, ChromolanBordeaux R, Croceine Scarlett MOO.

As mentioned before, the solvent has to be chosen very carefully as thisis one of the most essential factors on which the operativeness of theinvention depends. The solvent vehicle must have good dissolving powerfor the dye ingredients and for the resinous ingredients.

The difficulty of finding a proper solvent which would be compatible ina filler-stain composition with the use of acid organic dyestuffs haslimited the utility of thistype coloring matter in filler-stain mixtureprepared heretofore.

We have now found that tetrahydrofurfuryl alcohol has the desiredproperties of dissolving acid organic dyes, has high penetratingeiiiciency in wood, is compatible with some of the less expensive resinsolvents and has some dissolving power for resins.

Additional solvents approaching tetrahydrofurfuryl in dye solvency andeffectiveness of pene- "tration, are the hydroxyl bearing compounds, forexample, the ether-alcohols such as diethylene glycol monoethyl ether,and ethylene glycol monoethyl ether.

Less effective dye solvents characterized by the hydroxyl group andhaving compatibility with resin solvents therefor being useful for thisinvention, are the amino alkyl alcohols, for example, methyl aminopropanol, hydroxyl alicyclic compounds, such as cyclohexanol andheterocyclic ring alcohols, such as furfuryl alcohol.

In order to increase the rapidity of drying of the solvent vehicles,some low boiling compounds compatible with both the dye and resinsolvents, may be utilized as'diluents. Illustrative compounds of thisnature are the aliphatic alcohols, such as methyl and ethyl alcohol, andthe like, estersof the aliphatic alcohols, such as ethyl acetate, ethylpropionate, amyl acetate, and the like, and lzetones, such as acetoneand cyclohexanone.

We have also found that certain ingredients which give the compositionresistance to moisture retention are useful as solvents for resins andare compatible with the tetrahydrofurfuryl alcohol alone or whentetrahydrofurfuryl is mixed with other hydroxyl bearing compounds oflower solvency but higher volatility. These ingredients includehydrocarbon distillates, particularly toluol, xylols, ethyl benzene andsolvent naphtha.

Certain of the esters, such as butyl and amyl acetate, butyl propionate,are also useful for this purpose. These hydrocarbon distillates are alsocompatible with certain of the lower boiling alcohols, such as methyl,propyl and butyl alcohol, which are often added to these mixtures asdiluents which aid in the penetration and the evaporation of liquidconstituents of the stain and filler composition.

If desired, plasticizers may be added to the mixture. Tricresylphosphate is one of the many compounds suitable for this purpose. In thefollowing examples, a few embodiments of the invention, are illustrated:

Example I A solution of amberol 801 may be prepared by mixing thefollowing ingredients:

In a separate batch the following dye solution may be prepared:

0.5 part by weight Buffalo Black 2.8 parts by Weight Croceine ScarletMOO 1.7 parts by weight Metaline Yellow "50.0 parts by weighttetrahydrofurfuryl alcohol The dye solution is then mixed into theamberol solution. Thereafter the followingingredients may be added:

300 parts by weight calcium carbonate 8 parts by weight wood flour 4parts by weight polymerized organic salt of sulfonic acid of the alklyaryl type 12 parts by weight activated charcoal The mixture may then bemilled in a ball mill for 8 hours or passed through a 5-roll mill once.

Thereafter a thinner mixture composed of the following ingredients maythen be added:

.75 parts by weight methanol 250 parts by weight toluol or crude lightsolvent" .40 parts by weight ethylene glycol monomethyl ether Thecomposition of this example will yield a mahogany type finish.

Example II Another example for a mahogany type coating composition isgiven in the following:

4.0 parts by weight Gum Accroides Red 3.0 parts by weighttetrahydrofurfuryl alcohol 4.0 parts by weight dye solution (see below)30.0 parts by weight resin-coated calcium carbonate 3.0 parts by weightwood fiour 1.0 part by weight Burnt Umber 15.0 parts by weight toluol5.0 parts by weight methanol The dye solution used may be composed ofthe following:

0.5 part by weight Buffalo Black 2.8 parts by weight Brilliant Croceine3BA 1.7 parts by weight Metaline Yellow 50.0 parts by weighttetrahydrofurfuryl alcohol To one portion of the above composition maybe added 2 parts by weight of activated charcoal. To another portion ofthe above composition may be added 1 part by weight of carbon black.

The materials may be milled for identical periods, for example, 6 hoursin a ball mill.

Comparison of these two mahogany type stain and filler compositionsshows that upon wiping both surfaces the composition containingactivated charcoal wipes relatively clean, leaving evidence of charcoalalmost exclusively in the wood pores. On the other hand, a study of thesurface of the wood coated with the composition containing carbon blackshows evidence of carbon black scattered over the entire surface of thewiped wood, and the composition remaining on the surface of the wood hasa brownish muddy cast.

Example III 4.0 parts by weight :Gum Manila 8.0 parts by weightdiethylene glycol monoethyl ether 4.0 parts by weight dye solution ofExample II 30.0 parts by weight resin-coated calcium carbonate 4.0 partsby weight wood flour 2.0 parts by weight Burnt Umber 4.0 parts by weightactivated charcoal 13.0 parts by weight methanol 33.0 parts by weighttoluol This material is a heavy viscous liquid which should be milled aswith Example II. A proper thirmer to reduce to spraying consistency is:

5.0 parts by weight methanol 12.0 parts by weight toluol It will beunderstood that the color of the compositions of the examples may bechanged at will by merely altering the dyestuffs used.

The stain-fillers described are intended for spray application, but theyalso may be applied by brushing or dipping or any other means known tothe art. In all cases, wiping after an initial partial drying ofapproximately 5 to 15 minutes is necessary in order to remove any excessof the composition.

The coated articles are then dried either in aid or in a drying device,to a state of complete dryness. This drying is efiected at a temperaturein the range of 100 F. to 200 F., preferably at about 120 F., so thatliberation of moisture by the wood through its coating is prevented.

It will also be understood that while there have been described hereincertain specific embodiments of the invention, it is not intendedthereby to have the invention limited to or circumscribed by the detailsgiven herein in view of the fact that the invention is susceptible tovarious modifications and changes which come within the spirit of thedisclosure and the scope of the appended claims.

I claim:

1. A wood staining and filling composition consisting of 4.0 parts byweight Gum Manila 8.0 parts by weight diethylene glycol monoethyl ether4.0 parts by weight dye solution comprising a water soluble aniline dyedispersed in tetrahydrofurfuryl alcohol 30.0 parts by weightresin-coated calcium carbonate 4.0 parts by weight wood flour 2.0 partsby weight Burnt Umber 4.0 parts by weight activated charcoal 13.0 partsby weight methanol 33.0 parts by weight toluol and a thinner mixtureconsisting of:

5.0 parts by weight methanol 12.0 parts by weight toluol 2. A woodstaining and filling composition consisting of 4.0 parts by weight ofGum Manila; 8.0 parts by weight of diethylene glycol monoethyl ether;4.0 parts by weight of a dye solution consisting of 0.5 part by weightof Buifalo Black, 2.8 parts by weight of Brilliant Croceine 33A, 1.?parts by weight of Metanil Yellow, and 50.0 parts by weight oftetrahydrofurfuryl alcohol; 30.0 parts by weight of calcium carbonate;4.0 parts by weight of wood fiour; 2.0 parts by weight of Burnt Umber;4.0 parts by weight of activated charcoal; 13.0 parts by weight ofmethanol; 33.0 parts by weight of toluol; and a thinner mixtureconsisting of 5.0 parts by weight of methanol and 12.0 parts by weightof toluol.

3. A wood staining and filling composition consisting essentially of thefollowing ingredients in substantially the proportions given:

4.0 parts by weight Gum Manila 8.0 ipar-ts by weight diethylene glycolmonoethyl e her 4.0 parts by weight dye solution consisting of organicdyestuff dispersed in tetrahydrofurfuryl alcohol 30.0 parts by weightcalcium carbonate 4.0 to 18.0 parts by weight activated charcoal 18.0parts by weight methanol, and

45.0 par-ts by weight toluol JOHN W. MAYERS.

REFERENCES CITED vThe following references are of record in the file ofthis patent:

UNITED STATES PATENTS Number Name Date 1,316,674 Blackketter Sept. 23,1919 1,540,110 Dittmar June 2, 1925 1,913,329 Bradner June 6, 19332,000,121 Bush May '7, 1935 2,161,503 Bush June 6, 1939 2,338,149 WalkerJan. 4, 1944

1. A WOOD STAINING AND FILLING COMPOSITION CONSISTING OF: 4.0 PARTS BYWEIGHT GUM MANILA 8.0 PARTS BY WEIGHT DIETHYLENE GLYCOL MONOETHYL ETHER4.0 PARTS BY WEIGHT DYE SOLUTION COMPRISING A WATER SOLUBLE ANILINE DYEDISPERSED IN TETRAHYDROFURFURYL ALCOHOL 30.0 PARTS BY WEIGHTRESIN-COATED CALCIUM CARBONATE 4.0 PARTS BY WEIGHT WOOD FLOUR 2.0 PARTSBY WEIGHT BURNT UMBER 2.0 PARTS BY WEIGHT ACTIVATED CHARCOAL 13.0 PARTSBY WEIGHT METHANOL 33.0 PARTS BY WEIGHT TOLUOL 5.0 PARTS BY WEIGHTMETHANOL 12.0 PARTS BY WEIGHT TOLUOL.